Strategy to Manage Pump Interactions in Multi-Rig Applications

ABSTRACT

A system for managing a pump arrangement is provided. The system may include at least one pressure sensor configured to generate a pressure signal indicative of a pump pressure of a targeted pump within the pump arrangement, and at least one controller in electrical communication with the pressure sensor. The controller may be configured to receive the pressure signal from the pressure sensor, apply a band pass filter on the pressure signal to filter frequencies associated with untargeted pumps, isolate at least a base frequency of the filtered pressure signal, and detect at least the pump pressure of the targeted pump based on the base frequency.

TECHNICAL FIELD

The present disclosure relates generally to pump management systems, andmore particularly, to systems and methods for managing interactionsbetween pump sensors in a multi-rig application.

BACKGROUND

A hydraulic fracturing or fracking application generally involves theuse of multiple rigs, each having a fracking fluid pump that isconnected to a common manifold being supported by a missile trailer. Themanifold is further configured to deliver the collective pressurizedfluid to a wellhead and to equipment further downstream. Furthermore,each pump is provided with a pressure sensor which monitors the pump forexisting or anticipated fault conditions. Pressure sensors may typicallymonitor pump health based on the discharge pressure or other pumpattributes. In such fracking environments, or in any other multi-rig,multi-pump application where two or more pumps are situated inrelatively close proximity to one another and share a common manifold,there may be noticeable unwanted interactions between the adjacent pumppressures, which may adversely affect and compromise the overallintegrity of the management system.

In a typical multi-rig application, for instance, a pressure sensor thatis designated for a particular, targeted pump may inadvertently detector receive pressure fluctuations caused by or originating from adjacentand untargeted pumps, in addition to those pressures originating fromthe targeted pump. Although some of the undesired interferences may befiltered out using signal processes already built into the pressuremonitoring system, this is only possible when the base and/or harmonicfrequencies of the desired and undesired pressure signals, among others,are sufficiently distinguishable by the signal processes. Morespecifically, conventional pressure monitoring systems are unable tofilter out undesired pressure readings or interference from untargetedpumps and isolating the desired pressure readings from the targeted pumpif the base and/or harmonic frequencies coincide.

Although filtering schemes for use with pressure monitoring systems maybe available, there is still room for improvement. For example, U.S.Pat. No. 7,830,749 (“Kyllingstad”) discloses a method of filtering thatcan be used with pressure gauges designed to measure the dischargepressure of a piston pump. Moreover, Kyllingstad is directed tofiltering out noise attributed to the operation of the pump itself usingmathematical noise models specific to the given pump, and therebyproviding a cleaner reading of the pump condition. While the methodsdisclosed in Kyllingstad filter undesired noise, Kyllingstad is unableto filter and/or distinguish between signals originating from two ormore pumps when the pumps are operating at similar pump speeds, such asin a multi-pump fracking site or other multi-rig application.

In view of the foregoing disadvantages associated with conventionalpressure monitoring systems, a need therefore exists for a more reliablesolution that can easily be implemented in any applicable multi-pump ormulti-rig arrangement. Moreover, there is a need to provide a pressuremonitoring system which efficiently and effectively accounts forundesired interactions between neighboring pumps within a multi-pumparrangement, such as in a fracking site, to provide more accurateindications of the condition of each of the plurality of pumps.

SUMMARY OF THE DISCLOSURE

In one aspect of the present disclosure, a system for managing a pumparrangement is provided. The system may include at least one pressuresensor configured to generate a pressure signal indicative of a pumppressure of a targeted pump within the pump arrangement, and at leastone controller in electrical communication with the pressure sensor. Thecontroller may be configured to receive the pressure signal from thepressure sensor, apply a band pass filter on the pressure signal tofilter frequencies associated with untargeted pumps, isolate at least abase frequency of the filtered pressure signal, and detect at least thepump pressure of the targeted pump based on the base frequency.

In another aspect of the present disclosure, a controller for managing atargeted pump in a pump arrangement is provided. The controller mayinclude a receiver module, a filter module, and a detection module. Thereceiver module may be configured to receive a pressure signal from apressure sensor associated with the targeted pump. The filter module maybe configured to apply a band pass filter on the pressure signal tofilter frequencies associated with untargeted pumps and isolate at leasta base frequency of the targeted pump. The detection module may beconfigured to detect at least a pump pressure of the targeted pump basedon the base frequency.

In yet another aspect of the present disclosure, acontroller-implemented method for managing a pump arrangement having atargeted pump and one or more untargeted pumps is provided. Thecontroller-implemented method may include receiving a pressure signalfrom a pressure sensor associated with the targeted pump; applying aband pass filter on the pressure signal configured to filter frequenciesassociated with the untargeted pumps; isolating at least a basefrequency of the targeted pump based on the filtered pressure signal;and detecting at least a pump pressure of the targeted pump based on thebase frequency.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a pictorial illustration of one exemplary pump managementsystem that is implemented at a fracturing site;

FIG. 2 is a schematic illustration of one exemplary pump managementsystem of the present disclosure;

FIG. 3 is a schematic illustration of one exemplary controller of a pumpmanagement system of the present disclosure;

FIG. 4 is a graphical illustration of a pressure signal corresponding tothe discharge pressure of a targeted pump;

FIG. 5 is a graphical illustration of base and harmonic frequencies ofthe pressure signal of FIG. 4;

FIG. 6 is a graphical illustration of pressure signals corresponding tothe discharge pressures of a targeted pump and untargeted pumps;

FIG. 7 is a graphical illustration of base and harmonic frequencies ofthe pressure signals of FIG. 6;

FIG. 8 is a graphical illustration of a band pass filter being appliedonto pressure signals originating from targeted and untargeted pumpshaving sufficiently distinguishable pump speeds;

FIG. 9 is a graphical illustration of a band pass filter being appliedonto pressure signals originating from targeted and untargeted pumpshaving substantially the same pump speeds; and

FIG. 10 is a flowchart illustrating one exemplary method of the presentdisclosure for managing pump interactions.

DETAILED DESCRIPTION

Referring now to FIG. 1, one exemplary pump management system 100 thatmay be implemented at a fracturing site 102 and used to manageinteractions between pumps is provided. As shown, the fracturing site102 may include a multi-rig application, or sets of rigs, trucks ortrailers each performing a designated role necessary for fracking at agiven wellhead 104. For example, a fracturing site 102 may generallyinclude water supply rigs 106 for storing water, chemical storage rigs108 for storing chemicals to be mixed with the water, mineral storagerigs 110 for storing sand or other minerals to be used for fracking,blender rigs 112 for mixing the chemicals and sand with water, pump rigs114 which pump and pressurize the mixture to be discharged, and amanifold rig 116 which combines the mixture discharged by each of thepump rigs 114 and sends the pressurized mixture into the wellhead 104.The fracturing site 102 may further include a local data center 118 fromwhich the fracking operations may be managed. Furthermore, the pumpmanagement system 100 may be implemented directly on the one or more ofthe pump rigs 114, within the data center 118, or combinations thereof.In still further alternatives, the pump management system 100 may bepartially implemented and/or operated from a remote site via one or morewired and/or wireless networks.

Turning to FIG. 2, one exemplary embodiment of the pump managementsystem 100 that is implemented in relation to a set of pump rigs 114 andan associated pump arrangement 120 is provided. In general, the pumpmanagement system 100 may include one or more pressure sensors 122 andone or more controllers 124 in electrical communication with thepressure sensors 122. Moreover, each individual pressure sensor 122 maybe disposed in fluid communication with a discharge port of anassociated or targeted hydraulic pump 126 and configured to generate apressure signal indicative of at least pump pressure information of thetargeted pump 126. Each pressure sensor 122 may also generate a pressuresignal that is additionally indicative of pump failure information, orinformation relating to any detected or anticipated fault conditions orfailures in the targeted pump 126. Pump pressure information may bemonitored, measured or derived based on pump speed, discharge pressure,or the like, while pump failure information may be monitored, measuredor derived based on pump speed, discharge pressure, vibrations in thepump 126, or the like.

Still referring to FIG. 2, the pump management system 100 may employ anyone of a variety of different arrangements of controllers 124. As shown,a controller 124 may be provided for each individual pump rig 114, andconfigured to communicate with the pressure sensor 122 and/or pump 126associated therewith. Alternatively, a central controller 124 may beprovided and configured to communicate with multiple pressure sensors122 and/or associated pumps 126. In other embodiments, two or more ofcontrollers 124 may operate in conjunction with one another tocollectively communicate with a single pressure sensor 122 and/orassociated pump 126. Additionally, one or more of the controllers 124may be remotely situated relative to the fracturing site 102 andconfigured to indirectly communicate with one or more of the pressuresensors 122 via networking devices, or the like. Furthermore, while thecontrollers 124 may be directly integrated into the electronic controlmodule (ECM) or electronic control unit (ECU) of the associated pump rig114, the controllers 124 may alternatively be implemented using any oneor more of a processor, a microprocessor, a microcontroller, a fieldprogrammable gate array (FPGA), a programmable read-only memory (PROM),or any other device that can be operated in accordance withpreprogrammed instructions and/or algorithms disclosed herein.

Turning to FIG. 3, one exemplary embodiment of a controller 124 that maybe used in conjunction with the pump management system 100 is provided.As shown, for example, the controller 124 may be preprogrammed accordingto one or more algorithms generally categorized into a receiver module128, a filter module 130, a detection module 132, a comparison module134, and an adjustment module 136. The receiver module 128 may beconfigured to receive pressure signals 138, as shown in FIG. 4 forexample, from one or more pressure sensors 122 associated with thetargeted pump 126, where the pressure signals 138 may include pumppressure information, pump failure information, and any other relevantinformation the associated pressure sensor 122 is capable of reading.More particularly, as shown in FIG. 5, the pressure signals 138 mayinclude a base frequency 140 and one or more harmonic frequencies 142,which may correspond to the pump speed, discharge pressure, and/or otherattributes of the targeted pump 126. In other embodiments, the pressuresignals 138 may similarly include a failure frequency that is indicativeof any faults or failures in the targeted pump 126.

In actual practice, such as during a multi-rig fracking application, agiven pressure sensor 122 and/or corresponding controller 124 may pickup on not only the pressure signals 138-1 from targeted pumps 126-1, butalso pick up on unwanted pressure signals 138-2, 138-3 originating fromuntargeted pumps 126-2, 126-3, as illustrated in FIG. 2. As shown inFIG. 6, for example, the receiver module 128 of the controller 124 mayreceive pressure signals 138-2, 138-3 originating from one or moreadjacent untargeted pumps 126-2, 126-3 in addition to the desiredpressure signals 138-1 originating from the targeted pump 126-1. Asfurther shown in FIG. 7, the interaction of pressure signals 138received may reflect multiple base frequencies 140 and multiple sets ofharmonic frequencies 142 corresponding to the pump speeds and/ordischarge pressures of the untargeted pumps 126. Thus, the filter module130 of FIG. 3 may apply the appropriate filters configured to filter outany unwanted base frequencies 140-2, 140-3 associated with untargetedpumps 126-2, 126-3 that may be included in the pressure signals 138 dueto pump interactions, and isolate the base frequency 140-1 and anyfailure frequencies associated with the targeted pump 126-1.

As shown in FIG. 8, for example, the filter module 130 may be configuredto apply a band pass filter 144 that is centered on at least the basefrequency 140-1 of the targeted pump 126-1. By applying the band passfilter 144 on the pressure signals 138, the controller 124 may be ableto filter out other undesired frequencies which may have beeninadvertently received. Similarly, the filter module 130 may also beconfigured to center a band pass filter 144 on a failure frequency ofthe targeted pump 126-1 so as to filter out any other failurefrequencies originating from untargeted pumps 126-2, 126-3. Based on thefiltered pressure signals 138 and the isolated base frequency 140-1, thedetection module 132 of the controller 124 may be configured to detectthe discharge pressure of the targeted pump 126-1. The detection module132 may also be configured to detect pump failures of the targeted pump126-1 based on any failure frequencies that may be present in thefiltered pressure signals 138. In certain situations, however, the bandpass filter 144 may not be sufficient to isolate the base frequency140-1 of a targeted pump 126-1 if, for instance, the base frequencies140-2, 140-3, or corresponding pump speeds and/or discharge pressures,of the untargeted pumps 126-2, 126-3 are substantially the same as thoseof the targeted pump 126-1. Such situations may demand additional signalprocesses.

As shown in FIG. 9, for example, the base frequency 140-1 of thetargeted pump 126-1 may be the substantially the same as the basefrequencies 140-2, 140-3 of an untargeted pumps 126-2, 126-3. Moreover,the two base frequencies shown may be indistinguishable by the band passfilter 144 provided. In order to prevent such interactions from causinginaccurate pressure readings, the detection module 132 may also beconfigured to monitor pump speeds of the targeted pump 126-1 and theuntargeted pumps 126-2, 126-3. For example, the detection module 132 maydetect for situations where the pump speeds of the targeted pump 126-1and one or more untargeted pumps 126-2, 126-3 are substantially thesame, or for any other situation that could potentially result inoverlapping or substantially similar base frequencies 140 as shown inFIG. 9. While adjustments to the band pass filter 144 may be one way toisolate the base frequency 140-1 of the targeted pump 126-1, thecontroller 124 may implement amplitude-based techniques for isolatingthe base frequency 140-1 of the targeted pump 126-1.

If the detection module 132 detects that the pump speeds of the targetedpump 126-1 and one or more untargeted pumps 126-2, 126-3 aresubstantially the same, the comparison module 134 of the controller 124may compare the amplitudes of the base frequencies 140 provided in thepressure signals 138 to a theoretical amplitude or threshold 146 asshown in FIG. 9. The comparison module 134 may determine or lookup thetheoretical amplitude or threshold 146 based on the given pump speed ofthe targeted pump 126-1 by referring to a theoretical pump model, map,lookup table, or any other set of relationships between the pump speedand pressure signal amplitudes that may be preprogrammed into thecontroller 124. Additionally, the adjustment module 136 of thecontroller 124 may be configured to apply an adjustment factor to thepressure signals 138 based on the comparisons assessed by the comparisonmodule 134, so as to eliminate or reduce any existing base frequencies140-2, 140-3 originating from the untargeted pumps 126-2, 126-3. Inalternative embodiments, the controller 124 may be preprogrammedaccording to other combinations or arrangements of modules configured tocollectively provide comparable results. For instance, the controller124 may be programmed to perform amplitude-based assessments other thanthose performed by the comparison module 134 and the adjustment module136 in order to isolate the base frequency 140 of the targeted pump 126.

INDUSTRIAL APPLICABILITY

In general terms, the present disclosure sets forth techniques formanaging a pump arrangement, or more particularly, systems and methodsfor managing interactions between an arrangement of pumps simultaneouslyoperating in fluid communication with one another. Although applicableto any type of pump monitoring or management system, the presentdisclosure may be particularly applicable to pump arrangements in amulti-rig application, such as in a fracturing application, wheremultiple hydraulic pumps are used to discharge pressurized fluids into acommon manifold and where the individual pump pressures are susceptibleto influence by pressures from neighboring pumps. In general, thepresent disclosure employs a combination of band pass filters andtheoretical pump models to manage pump interactions. More specifically,the band pass filters are used to filter out unwanted pressure signalsoriginating from untargeted pumps, and isolate the desired pressuresignals originating from the targeted pump. In the event an untargetedpump is operating at a pump speed that is substantially the same as thatof the targeted pump, the theoretical pump model is used a reference,which can further be used to compare the respective amplitudes of thepressure signals at the appropriate frequencies, and distinguish betweenpressure signals belonging to the targeted pump and more attenuatedpressure signals belonging to any untargeted pumps.

One exemplary algorithm or controller-implemented method 148 formanaging interactions between hydraulic pumps 126 within a multi-pumparrangement 120 is diagrammatically provided in FIG. 10. As shown, thecontroller 124 in block 148-1 may be configured to continuously,periodically or intermittently receive pressure signals 138 from apressure sensor 122 of a targeted pump 126, where the pressure signals138 may include information pertaining to the pump speed, dischargepressure, fault events, and the like. In block 148-2, the controller 124may be configured to monitor the pump speed of the targeted pump 126relative to the pump speeds of adjacent untargeted pumps 126 todetermine if the pump speeds are substantially the same. If the pumpspeed of the targeted pump 126 is sufficiently distinguishable fromthose of other surrounding pumps 126, the controller 124 may proceed toblock 148-3 and apply one or more band pass filters 144 onto thepressure signals 138. Moreover, the band pass filter 144 may be centeredon the base frequency 140, one or more harmonic frequencies 142 thereof,and any failure frequencies of the targeted pump 126, so as to filterout undesired frequencies belonging to untargeted pumps 126 which mayhave been inadvertently received. Based on the filtered pressure signals138, the base frequency 140 and any harmonic frequency 142 and/orfailure frequency associated therewith, the controller 124 in block148-4 may be configured to extract information related to the dischargepressure, fault or failure events, and any other information relevant tothe targeted pump 126.

If, however, the controller 124 in block 148-2 of FIG. 10 determinesthat the pump speed of the targeted pump 126 is not sufficientlydistinguishable from an untargeted pump 126, the controller 124 mayproceed to block 148-5. More specifically, the controller 124 in block148-5 may apply one or more band pass filters 144 onto the pressuresignals 138 in a manner configured to filter out undesired frequenciesbelonging to any untargeted pumps 126. The controller 124 in block 148-6may additionally compare the amplitudes of the pressure signal 138 atthe appropriate frequencies, such as at the base frequency 140, harmonicfrequencies 142 and/or the failure frequency, with theoreticalamplitudes which may be derived from a preprogrammed theoretical pumpmodel, or the like. Based on the amplitude comparisons, the controller124 may be able to distinguish between amplitudes belonging to pressuresignals 138 originating from the targeted pump 126, and more attenuatedamplitudes belonging to pressure signals 138 originating from untargetedpumps 126. Furthermore, the controller 124 in block 148-7 may apply theappropriate adjustment factors to the pressure signals 138 based on theprevious comparisons in a manner configured to eliminate or sufficientlyreduce the undesired remnants in the pressures signals 138 originatingfrom the untargeted pumps 126, and extract information related to thedischarge pressure, fault or failure events, and any other informationrelevant to the targeted pump 126.

The controller 124 may thus obtain or determine the desired pumpinformation, such as information related to the discharge pressure,fault or failure events, and any other information relevant to thetargeted pump 126, via either block 148-4 or block 148-7 of FIG. 10. Thecontroller 124 in block 148-8 may additionally process the extractedinformation for further diagnostics and prognostics, which may be usedfor managing the pump arrangement 120. Alternatively, the controller 124may forward any extracted information to a central controller 124 and/ora data center 118 where more suitable resources for performing thediagnostics and prognostics may be available. From the foregoing, itwill be appreciated that while only certain embodiments have been setforth for the purposes of illustration, alternatives and modificationswill be apparent from the above description to those skilled in the art.These and other alternatives are considered equivalents and within thespirit and scope of this disclosure and the appended claims.

What is claimed is:
 1. A system for managing a pump arrangement,comprising: at least one pressure sensor configured to generate apressure signal indicative of a pump pressure of a targeted pump withinthe pump arrangement; and at least one controller in electricalcommunication with the pressure sensor, the controller being configuredto receive the pressure signal from the pressure sensor, apply a bandpass filter on the pressure signal to filter frequencies associated withuntargeted pumps, isolate at least a base frequency of the filteredpressure signal, and detect at least the pump pressure of the targetedpump based on the base frequency.
 2. The system of claim 1, wherein thepressure sensor is configured to generate pressure signals includingpump pressure information measured in terms of pump speed.
 3. The systemof claim 1, wherein the pressure sensor is configured to generatepressure signals including pump failure information measured in terms ofvibrations in the pump.
 4. The system of claim 1, wherein the controlleris configured to apply the band pass filter to isolate at least the basefrequency of the targeted pump.
 5. The system of claim 1, wherein thecontroller is configured to apply the band pass filter to isolate afailure frequency of the targeted pump, and detect a pump failure of thetargeted pump based on the failure frequency.
 6. The system of claim 1,wherein the controller is configured to detect when pump speeds of thetargeted pump and one or more untargeted pumps are substantially thesame, compare amplitudes of the detected base frequencies to atheoretical amplitude of the base frequency of the targeted pump at thegiven pump speed, and apply an adjustment factor to the pressure signalbased on the amplitude comparison to exclude base frequencies ofuntargeted pumps.
 7. A controller for managing a targeted pump in a pumparrangement, comprising: a receiver module configured to receive apressure signal from a pressure sensor associated with the targetedpump; a filter module configured to apply a band pass filter on thepressure signal to filter frequencies associated with untargeted pumpsand isolate at least a base frequency of the targeted pump; and adetection module configured to detect at least a pump pressure of thetargeted pump based on the base frequency.
 8. The controller of claim 7,wherein the receiver module is configured to receive pressure signalsincluding pump pressure information measured in terms of pump speed. 9.The controller of claim 7, wherein the receiver module is configured toreceive pressure signals including pump failure information measured interms of vibrations in the pump.
 10. The controller of claim 7, whereinthe filter module is configured to center the band pass filter on atleast the base frequency of the targeted pump.
 11. The controller ofclaim 7, wherein the filter module is configured to apply the band passfilter to isolate a failure frequency of the targeted pump, and thedetection module is configured to detect a pump failure of the targetedpump based on the failure frequency.
 12. The controller of claim 7,wherein the detection module is configured to detect when pump speeds ofthe targeted pump and one or more untargeted pumps are substantially thesame.
 13. The controller of claim 12, further comprising: a comparisonmodule configured to compare amplitudes of the detected base frequenciesto a theoretical amplitude of the base frequency of the targeted pump atthe given pump speed; and an adjustment module configured to apply anadjustment factor to the pressure signal based on the amplitudecomparison to exclude base frequencies of untargeted pumps.
 14. Acontroller-implemented method for managing a pump arrangement having atargeted pump and one or more untargeted pumps, comprising: receiving apressure signal from a pressure sensor associated with the targetedpump; applying a band pass filter on the pressure signal configured tofilter frequencies associated with the untargeted pumps; isolating atleast a base frequency of the targeted pump based on the filteredpressure signal; and detecting at least a pump pressure of the targetedpump based on the base frequency.
 15. The controller-implemented methodof claim 14, wherein the pressure signal includes at least pump pressureinformation measured in terms of pump speed.
 16. Thecontroller-implemented method of claim 14, wherein the pressure signalincludes pump failure information measured in terms of vibrations in thepump.
 17. The controller-implemented method of claim 14, wherein theband pass filter is centered on the base frequency and a failurefrequency of the targeted pump.
 18. The controller-implemented method ofclaim 17, further comprising: isolating at least the failure frequencyof the targeted pump based on the filtered pressure signal; anddetecting at least a pump failure of the targeted pump based on thefailure frequency.
 19. The controller-implemented method of claim 14,further comprising: detecting when pump speeds of the targeted pump andone or more untargeted pumps are substantially the same; comparingamplitudes of the detected base frequencies to a theoretical amplitudeof the base frequency of the targeted pump at a given pump speed; andapplying an adjustment factor to the pressure signal based on theamplitude comparison to exclude base frequencies of untargeted pumps.20. The controller-implemented method of claim 19, wherein detectedfailure frequencies caused by interactions with pressure sensorsassociated with one or more untargeted pumps are also excluded based onamplitude comparisons and adjustment factors.